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INCORPORATED

Owner's Manual for ONICON Insertion Turbine Flow Meters

Insertion Flow Meters are available in Single or Dual Turbine. This manual applies to all Insertion Flow Meters. For use with serial numbers 115692 and later

1500 North Belcher Road, Clearwater, Florida 33765 Tel (727) 447-6140 Fax (727) 442-5699 www.onicon.com E-mail: sales@onicon.com

9-27-01

SAFETY INFORMATION
Throughout this manual some text appears in bold type. These statements contain information related to safety issues. Many installations of our meters will be in high pressure or high temperature systems and accidents with these systems can cause serious injury or death to those working on them or standing nearby. There is also the possibility of property damage.

Please pay extra attention to these areas of bold text.

The information in this manual has been carefully checked for accuracy. There is, however, the possibility of omission or error. In such an event, ONICON Incorporated does not assume liability for any damages resulting from the use of this manual.

SERVICE
If ONICON equipment requires servicing, we prefer to have it returned to the factory. In some cases you may want to service it yourself. Our technical staff will be happy to work with you in these cases; however, we request that you contact us before beginning to work on the equipment because we can provide helpful information which is beyond the scope of this manual.

Owners Manual for ONICON Insertion Turbine Flow Meters September 27, 2001

TABLE OF CONTENTS
1.0 INTRODUCTION ..................................................................................................3 1.1 Purpose of This Guide..............................................................................3 1.2 A Typical Insertion Turbine Flow Meter ................................................3 1.3 Standard Features and Specifications.....................................................4 1.4 Installation Hardware...............................................................................5 1.5 Model Numbering System .......................................................................5 1.6 Warranty and Serial Number ...................................................................6 UNPACKING..........................................................................................................7 2.1 Checking That You Have Received Everything ......................................7 INSTALLATION, REMOVAL & ADJUSTMENT ..................................................8 3.1 Site Selection............................................................................................8 3.2 Mechanical Installation..........................................................................10 3.3 Insertion of the Meter.............................................................................11 3.4 Removal of the Meter .............................................................................12 3.5 Adjustment of the Meter ........................................................................13 3.6 Wiring Connections................................................................................14 START-UP & COMMISSIONIING FOR ONICON INSERTION TURBINE FLOW METERS..................................................................................15 4.1 Helpful Hints for Start-up and Commissioning....................................15 4.2 Start-up and Commissioning .................................................................16 4.3 Start-up and Commissioning Worksheet ..............................................17 4.4 Troubleshooting Guide ..........................................................................18 ANALOG ADJUSTMENT PROCEDURE.............................................................19 5.1 General Discussion.................................................................................19 5.2 Analog Adjustment Procedure ..............................................................20 APPENDICES A B C User Connections and Internal Wiring Diagrams Turbine Assembly Detail Drawings Conditions of Sale

2.0

3.0

4.0

5.0

Owners Manual for ONICON Insertion Turbine Flow Meters September 27, 2001

SECTION 1.0: INTRODUCTION


We, at ONICON INCORPORATED, would like to thank you for purchasing our quality U.S. made Insertion Turbine Flow Meter. As our valued customer, our commitment to you is to provide fast reliable service and assistance, while continuing to offer you new products to meet your growing flow measurement needs. 1.1 PURPOSE OF THIS GUIDE

We have written this guide to provide the persons responsible for the installation, operation and maintenance of your insertion flow meter with the most specific equipment information they will need. This is NOT an electrical or plumbing trade manual. PLEASE DO NOT PERMIT ANY PERSONS TO INSTALL, OPERATE OR MAINTAIN THIS EQUIPMENT UNLESS THEY HAVE A COMPLETE KNOWLEDGE OF THEIR TRADE SKILLS AND ARE COMPETENT TO WORK ON HIGH VOLTAGE POWER WIRING OR HIGH PRESSURE HOT AND COLD WATER AND STEAM SYSTEMS, ACCORDING TO THEIR INDIVIDUAL TRADES. DEATH OR PERMANENT INJURY MAY RESULT FROM ACCIDENTS WITH THESE SYSTEMS. This guide is the basic reference tool for all ONICON Insertion Turbine Flow Meters. If you have not purchased all of the options, there will be references in this manual which are not applicable to you meter(s).

1.2

A TYPICAL INSERTION TURBINE FLOW METER

ONICONs Insertion Turbine Flow Meters measure the velocity of flowing liquids by counting the frequency at which the blades of a rotating turbine pass a fixed electrode. Circuitry within the flow meter electronics enclosure then converts the rotational rate to digital and/or analog signals which are transmitted via a connecting cable to any of ONICONs display devices, BTU meters and/or a data acquisition system.

Owners Manual for ONICON Insertion Turbine Flow Meters September 27, 2001

1.3

STANDARD FEATURES AND SPECIFICATIONS

(Refer to specification sheet for particular model for additional details) F-1100 Series Accuracy 0.5% OF READING at calibrated velocity 1% OF READING from 3 to 30 ft/s (10:1 range) 2% OF READING from 0.4 to 20 ft/s (50:1 range) Sensing Method Electronic impedance sensing (non magnetic and non-photoelectric) Pipe Size Range 1 through 72 nominal Supply Voltage 244 V AC/DC at 50 mA Liquid Temperature Range Standard: 180 F continuous, 200 F peak High Temp: 280 F continuous, 300 F peak Meters operating above 250 F require 316 stainless steel construction option Ambient Temperature Range -5 to 160 F (-20 to 70 C) Operating Pressure 400 PSI maximum Pressure Drop Less than 1 PSI at 20 ft/s in 1 pipe, decreasing in larger pipes and lower velocities Material Wetted metal components Standard: Electroless nickel plated brass Optional: 316 stainless steel Electronics Enclosure Standard: Weathertight aluminum enclosure Optional: Submersible enclosure Electrical Connections Standard: 10 of cable with NPT conduit connection Optional: Indoor DIN connector with 10 of plenum rated cable Output Signal(s) Standard: Calibrated frequency output (0-15v pulse) Optional: Analog and Digital outputs also available, based on model F-1200 Series This series has all of the features of the F-1100 series plus: Dual Turbines and frequency output averaging circuitry to provide improved Accuracy in short pipe runs. Pipe size range is 2 through 72 nominal FB-1200 Series This series has all the features of the F-1200 series plus: Capability of detecting and reporting flow direction

Owners Manual for ONICON Insertion Turbine Flow Meters September 27, 2001

1.4

INSTALLATION HARDWARE

All ONICON insertion type meters can be installed and removed via a 1 or larger full port ball valve without system shutdown. The terms Standard and Hot Tap refer to the installation method of the isolation valve kit only.

Standard Installation Hardware: For new construction or scheduled shutdown. Once kit is installed, the flow meter can be installed or removed without system shutdown.

Hot Tap Installation Hardware: For applications which require the access hole in the pipe to be drilled through the valve using a wet tap drilling machine, while the hydronic system is pressurized and operating.

1.5

MODEL NUMBERING SYSTEM F(B)-XX YY

SERIES F-11 F-12 FB-12 F-13 Single Turbine, Insertion Type Dual Turbine, Insertion Type 10 Bi-Directional, Insertion Type Inline Turbine Meter 11 00

OUTPUT SIGNAL Frequency Output (15 V pulse)


For connection to Onicon display or BTU meter only. Signal is too fast for most building control systems (0-300 hz).

Analog Output (non-isolated)


Provides both 4-20 mA and 0-10 V outputs. Most commonly used output type. (3-wire connection)

Isolated Analog Output


Provides both 4-20 mA and 0-10 V outputs. Signal ground is isolated from power supply and pipe ground. (4-wire connection)

Example: F-1210 = Dual turbine, analog output

20

Divided Output
(Solid state dry contact)
Provides an isolated binary/digital output. Signal is divided to limit the maximum frequency. For rate/totalization.

30

Scaled Output
(Solid state dry contact)
Provides an isolated binary/digital output scaled to provide one pulse per desired unit volume (i.e.: 1 pulse = 10 gal.). Ideal for totalization applications.

Owners Manual for ONICON Insertion Turbine Flow Meters September 27, 2001

1.6

WARRANTY AND SERIAL NUMBER

Warranty ONICONs complete warranty is included in Appendix C of this manual as a part of the Conditions of Sale. Meters purchased after November 1, 2000 include a two-year No fault warranty which may cover accidental damage caused during installation or start up.

Serial Number The serial number of your Insertion Flow Meter is located on a label on the side of the electronics enclosure. The model number is also listed on this label. The serial number is a unique identifier that you should refer to, along with the model number, whenever you require assistance regarding your meter.

Owners Manual for ONICON Insertion Turbine Flow Meters September 27, 2001

SECTION 2.0: UNPACKING


Insertion Flow Meters are generally shipped in one package unless optional hardware or equipment is ordered. This package may contain up to two complete meters along with the optional installation kits. If any display equipment was ordered with the meters, the other equipment will be packed separately. Please open all packages with caution to prevent damage to their contents. In the event that they are damaged when you receive them, notify the shipping company immediately and the ONICON Customer Service Department. All products are shipped insured unless customer specifically requests otherwise. 2.1 CHECKING THAT YOU HAVE RECEIVED EVERYTHING The Documentation Enclosed with each Insertion Flow Meter is a comprehensive documentation package which includes the following items: !"OWNERS MANUAL !"FLOW METER CALIBRATION DATA SHEETS Please notify the ONICON customer service department if any of these documents are missing.

The Flow Meter The flow meter is a rugged instrument and should arrive without any damage; however, prior to installation, inspect it for physical damage such as broken turbine blades or a damaged stem. !"Test the turbine(s) to see that they rotate freely when you blow on them parallel to their shafts. !"Make sure that the threads on the hot tap adapter have not been damaged. !"Inspect the long stem for bends or other damage. The stem forms the seal against liquid leakage as it slides through an O ring outside the hot tap adapter. Deep scratches may cause leakage. !"The serial and model numbers on the wire connection/calibration data tag should match the numbers on the tag mounted directly on the flow meter. Be sure that the unit was calibrated to the correct pipe size and flow range.

Owners Manual for ONICON Insertion Turbine Flow Meters September 27, 2001

SECTION 3.0: INSTALLATION, REMOVAL & ADJUSTMENT


***CAUTION*** Insertion Flow Meters may often be installed in pipes which are under high pressure. Accidents with these systems can cause serious injury or death. Only persons experienced with high pressure systems and related knowledge in the heating, cooling and fluid metering fields should attempt to install adjust or remove the flow meter. Refer to the installation drawings before performing any work on these meters.

ONICON will be happy to assist with technical recommendations and to provide guidance by telephone and/or mail. On-site field engineering, installation and service is also available at additional cost. 3.1 SITE SELECTION

Install the flow meter where it will be accessible for personnel to perform necessary periodic maintenance. The clearance required for installation is typically 30-36 from the pipe wall to the nearest obstruction above the valve assembly. This clearance dimension will increase with large diameter pipes. The environment should be free of corrosive liquids/fumes, temperature extremes and heavy vibration. The following diagrams should be used as a guide to the proper location for installing the meter.

If yours is a single turbine meter and there is no suitable location, contact ONICONs Sales Office to discuss upgrading to a dual turbine meter. This meter is more tolerant of the conditions that cause swirl, turbulence and flow profile distortions. Please make this decision before installing the single turbine meter so that we may be able to give you credit if you elect to upgrade to a dual turbine meter. Returns may be subject to a restocking charge.

Owners Manual for ONICON Insertion Turbine Flow Meters September 27, 2001

Owners Manual for ONICON Insertion Turbine Flow Meters September 27, 2001

3.2

MECHANICAL INSTALLATION

Turbine meters may require periodic maintenance and you should be able to remove the meter when necessary without shutting down your system. To take advantage of the ONICON Flow Meters built-in Hot Tap feature, it must be installed through an isolation valve. The location must allow sufficient overhead clearance for meter removal (for cleaning and preventative maintenance). A full 1 opening is required to clear the turbine assembly. Make sure that your valves and fittings are full port and at least 1 in actual internal diameter. Also, note that an oversized access hole can cause undesirable turbulence. Try to limit the overall height from the pipes outside diameter to the top of the valve to 5 6. ONICON calculates the stem length of the flow meter based on pipe size and this nominal height. If your installation requires a taller fitting assembly and the dimension was not specified on the order form, please contact the factory before installation. This way ONICON can offer you credit for your meter if you decide to exchange it for one with a longer stem. Returns may be subject to a restocking fee. ONICONs Standard Installation Hardware kit is for use in a drained, non-pressurized system. The access hole is drilled (1 minimum) prior to installation of the 1 NPT branch outlet, close nipple and full port ball valve. Once the isolation valve is installed, the piping system can be flushed and pressurized. The flow meter may now be inserted or removed by hand without having to drain the system. Please read all instructions before proceeding with meter insertion. ONICONs Hot Tap Installation Hardware kit offers an alternative installation when it is not practical to drain or relieve the pressure in the system. In this case, a 1 branch outlet, close nipple and 1 full port ball valve are installed first. Then, a hot tap drilling apparatus can be used to drill a 1 diameter hole through the valve, without shutting down or draining the pipe.

Owners Manual for ONICON Insertion Turbine Flow Meters September 27, 2001

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When you are ready to refill the system, make sure that all lines are filled with water before inserting the turbine into the stream. If the lines are not filled, air may interrupt the flowing stream and damage the turbine assembly. A greater danger is that if this is a hot water system, some water may flash into steam and exceed the high temperature limit for the turbine and its mechanical assembly. This flash over could exceed the pressure ratings of the meter and the assembly could fail allowing steam and hot water to escape causing serious injury.

After fitting the necessary plumbing hardware, flush the entire system so that it is free of flux, solder and slag. Prepare to install the flow meter by loosening the clamping nut and withdrawing the turbine assembly fully into the hot tap adapter. Next, thread the adapter on to the ball valve using a paste type thread sealant. Do not use Teflon tape because torn strands of the tape may wind around the turbine, slowing down or even stopping the turbine.

Check the installation for leaks by slightly opening the ball valve under the hot tap adapter. An O ring in the adapter seals the meter stem against leakage. If there are any leaks around the clamping nut or stem, DO NOT ATTEMPT TO STOP THE LEAKAGE BY OVERTIGHTENING THE CLAMPING NUT. Damage to this nut or the clamping ring under the nut may prevent the assembly from properly holding the meter in the pipe. The clamping nut is not part of the sealing mechanism. Any leaks in this area indicate that the O ring is not sealing properly and you must contact the factory for assistance. 3.3 INSERTION OF THE METER ***CAUTION*** SYSTEM MAY BE UNDER HIGH PRESSURE. When adjusting the meter position or removing it, be sure to hold the electronics enclosure firmly by hand before SLOWLY loosening the positioning clamping nut. Failure to do this will allow the pressure to suddenly and rapidly force the meter from the pipe causing serious injury. The meter could also be damaged or break apart causing a break in the water seal with the resultant loss of large amounts of water. The hand effort required to hold the meter will be 0.11 times the pipe pressure. Begin by calculating the effort that will be required to hold the meter. Establish adequate footing for this task, taking extra caution when working from a ladder or platform. Use the following formula: E=0.11xP Where: E = effort in pounds P = system pressure in pounds per square inch
Example: In a 300 PSI system, 33 pounds of effort is required to insert the meter into the pipe.

Owners Manual for ONICON Insertion Turbine Flow Meters September 27, 2001

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Installing the meter with a factory supplied depth gage: 1. Open valve completely, loosen the position clamping nut, and insert the meter until the bottom of the electronics case touches the eye of the depth gage. (Pierce insulation with gage until the tip touches the pipe.) 2. Position the electronics enclosure parallel to the pipe in the direction relative to the flow. This will position the turbine with its axis in line with the flow and in the correct direction. 3. Tighten the position clamping nut.

Do not release the flow meter until you have tightened the position clamping nut enough to hold the flow meter in the desired position. This will require less torque than you might think, so be careful not to overtighten it and risk damaging the adapter, nut or stem.

Installing the meter without a gage: (Contact the factory for assistance)

NOTE: For installations with a limited straight run of pipe (less than the recommended distances shown on pages 9 and 10),adjustments in insertion depth may be needed to compensate for velocity flow profile variations. Please contact the factory for information on velocity flow profiling for determining the average velocity location in undeveloped flow locations.

3.4

REMOVAL OF THE METER ***CAUTION*** Remember, the meter may be under high pressure, and while removal of the meter is basically the reverse of the insertion procedure detailed above, care must be taken to ensure that the meter is supported against the pipe pressure before the position clamping nut is loosened. Failure to do this will allow the pressure to suddenly and rapidly force the meter from the pipe causing serious injury.

Prior to removal of the meter, make sure that you are standing on a secure platform and have both hands available to manipulate the flow meter.

Owners Manual for ONICON Insertion Turbine Flow Meters September 27, 2001

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First support the flow meter against the pipe pressure by holding the electronics enclosure firmly in hand BEFORE loosening the position clamping nut. The effort which will be required is the same as that required for insertion of the meter and should be calculated according to the formula in the prior section covering insertion of the meter. This effort will be 0.11 times the pipe pressure. If your footing is not secure, or if your ability to hold the meter limited for any reason, DO NOT loosen the clamping nut.

SLOWLY loosen the position clamping nut and carefully and slowly allow the pressure to force the meter out of the pipe. This is not at all difficult, but you must not let go of the meter until it is fully withdrawn into the hot tap adapter. After the meter is completely withdrawn, you may close the isolation ball valve. The main cause of damage to meters comes from accidentally closing the valve on the turbine assembly. To avoid this, gently rotate the meter by twisting the electronics enclosure back and forth (twist the stem, do not bend it) while you slowly close the valve. If the valve touches any part of the meter, you will feel it as you are twisting the meter. If the valve touches anything, it means the meter is not fully withdrawn. Usually a gentle twisting motion while withdrawing the meter will clear any obstruction and permit the meter to withdraw completely. (Excessive build-up on the stem may require the hot tap O ring to be lubricated with silicone.) After the valve is completely closed, you can safely unscrew the hot tap adapter from the valve. Partially unscrew the adapter and allow pressure to vent from the hot tap adapter. There will be very little water in the hot tap adapter; however, a small bucket or pan should be held under the valve to catch any spilled water.

***CAUTION***

!
3.5

In hot water systems, even a small amount of water can cause serious personal injury. Use extra caution when working with hot water meters.

ADJUSTMENT OF THE METER

***CAUTION*** If adjustment of the meter depth is required, the same procedure must be followed as if the meter was being removed. Please carefully read the section above on removal of the meter. Remember, the meter may be under high pressure and failure to follow the procedure may result in serious injury. Once the meter has been moved to its new depth, tighten the position clamping nut. Next, place several turns of electrical tape around the stem just above the clamping nut so that at a later time, when the meter is removed for service, it can be easily replaced at the same depth.

Owners Manual for ONICON Insertion Turbine Flow Meters September 27, 2001

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3.6

WIRING CONNECTIONS

Make connections to the 10 cable, which is supplied by ONICON and is pre-wired to the circuit board. Do not attempt to make any connections inside the electronics case, or to remove factory installed connection fittings. Damage resulting from these actions may not be covered under warranty.

The most common cause of electronic failure is incorrect connection. If you will be adding any additional cable, please record any substitution of wire colors. If additional cable is purchased from ONICON, the color code can be maintained. However, cable from other sources will most likely have a different set of colors. Please refer to Appendix A for wiring diagrams and factory color codes. Only qualified service personnel should make connections between the Insertion Flow Meter and the users external equipment. Any misapplication of power and/or ground can result in improper operation of the unit or damage to the Insertion Flow Meter, the flow meter circuitry, and to any externally connected equipment.

Owners Manual for ONICON Insertion Turbine Flow Meters September 27, 2001

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SECTION 4.0: STARTUP & COMMISSIONING FOR ONICON INSERTION TURBINE FLOW METERS

4.1

HELPFUL HINTS FOR START-UP AND COMMISSIONING

A step-by step procedure and companion worksheet are located on the next two pages. Please read all installation instructions carefully before proceeding with installation, start-up and commissioning.

Please read these helpful hints before proceeding with the start-up and commissioning procedure on the next page. 1. ONICON Flow Meters are individually calibrated for a particular application. Be sure to verify the pipe size and location. 2. The electronic sensing systems will not work in air. Blowing on the turbine(s) will not produce a signal. You can test the meter by holding the turbines under a faucet or carefully moving it back and forth in a bucket of water. 3. When measuring analog output signals, remember that currents (mA) must be measured in series, while voltages are measured in parallel. If the 4-20 mA signal is already connected to a control system, you must break the connection and measure the signal in series. 4. When measuring frequency outputs in hertz, take your multimeter out of autorange mode and manually set range for a voltage level above 15 VDC. This will prevent false readings when no turbine signal is present. 5. All wiring connections should be made at the end of the factory cable. Do not attempt to remove the factory installed cable or change the orientation of the electronics enclosure. 6. Never connect power to analog or frequency output signal wires. ONICON flow meters are not loop powered devices.

Owners Manual for ONICON Insertion Turbine Flow Meters September 27, 2001

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4.2

START-UP AND COMMISSIONING

Please read the entire procedure carefully before proceeding. Wiring diagrams are located in the appendix. A worksheet for checking off the following steps and recording measured values is located on the following pages.
Is the meter located in the correct location as required by the plans?

1.

Confirm meter location and adequate straight pipe run to achieve desired results

Compare actual straight pipe upstream and downstream of the meter location to recommended distances identified in the installation manual. Note that the manual is very conservative, assuming worst-case pipe obstructions; contact ONICONs technical support department to discuss specifics of your application. If straight pipe run is very short, consult factory PRIOR to installing a single turbine meter to discuss possibility of upgrade to a dual turbine meter. Confirm that the meter is tagged for the pipe size it is installed in. When in doubt, measure the circumference of the pipe. Pipe O.D. = (circumference / 3.14) (insulation thickness x 2) Each flow meter comes with an attached insertion gage and instruction tag. Ensure that meter is inserted to correct depth and that the electronics enclosure is parallel with the pipe, with the arrow in the direction of flow. Confirm that the control system input point is properly configured for the analog range (or binary scale factor) identified on the flow meter calibration tag & certificate. Confirm that the flow meter serial number matches the ONICON display or BTU meter serial number (when ordered together) Prior to connecting the power, verify that wiring is correct as shown in this manual and/or additional wiring diagram provided with ONICON display or BTU meter. If in doubt, call factory for assistance before proceeding further. Verify that 24 (+/- 4) V is available. Serial Numbers 115692 and later can accept 24 V DC or AC, but earlier meters required 24 VDC. Note: ONICON display module or BTU Meter provides 24 VDC to the flow meter. ONICON display modules and BTU meters are typically powered by 120 VAC, however, low voltage versions are also available. Wait approximately 45 seconds after power-on before proceeding further.

2. 3. 4. 5. 6.

Confirm Pipe Size Confirm insertion depth and orientation Confirm control system programming Confirm connection to correct ONICON display or BTU Meter (if ordered) Verify wiring before connecting power Confirm correct supply voltage Connect power

7. 8.

The following steps require flow in the pipe. Flow signal readings should be taken while holding the flow rate constant if possible, otherwise, take the various output readings as quickly as possible.
The average frequency output signal is a 0-15 VDC pulsed output ranging up to 200 Hz and must be measured with a frequency counter or oscilloscope. Measure DC Frequency (Hz) from GREEN(+) to BLACK(-). Also measure DC volts on same wires. 5 to 7 VDC is normal for a spinning turbine, 0 or 14+ VDC indicates a stopped turbine. (1 to 4 VDC could indicate a problem) GPM = Frequency in Hz X 60 Meter Factor in ppg (refer to calibration tag for meter factor) For Dual Turbine Models, also measure and record the top and bottom turbine signals TOP: WHITE(+) to BLACK(-) BOTTOM: ORANGE(+) to BLACK(-)

9.

Measure and record frequency output(s):

Measure and record analog or binary outputs


Current Output:

Refer to flow meter wiring diagram for wire colors for the various outputs available, based on your particular flow meter model. Use the following formulas to calculate flow rate from measured analog signals: GPM = (measured current in mA - 4) X Full Scale Analog Flow Rate 16 GPM = measured DC volts X Full Scale Analog Flow Rate 10 Same calculation as step 9, except use divided meter factor (measure and record frequency) Each contact closure = unit volume identified as Scale Factor (measure and record time interval between contact closures) The top and bottom turbine frequencies (dual) should be within about 20% of each other and their average should equal the average frequency output. Compare the flow rates calculated in STEPS 9 and 10 to each other and to the flow rate indicated by the control system. Refer to troubleshooting guide when readings are inconsistent.

10.

Voltage Output: Divided Output: Scaled Output:

11.

Compare various output signals to each other and to the flow rate displayed by the control system

End of standard start-up and commissioning. Please contact ONICONs technical service department at (727) 447-6140 with any questions.

Owners Manual for ONICON Insertion Turbine Flow Meters September 27, 2001

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4.3 START-UP AND COMMISSIONING WORKSHEET Please read all installation instructions carefully prior to proceeding with these steps. Wiring diagrams are located in the appendix. Use the following worksheet for checking off the commissioning steps and recording measured values: STEP 1. 2. 3. 4. 5. 6. 7. 8.
TEST / MEASUREMENT Meter location Confirm pipe size Insertion depth and orientation Control system programming Match display or BTU meter serial#(if ordered) Signal Connections Verified Supply voltage verified Connect power S/N: 1 S/N: 1 S/N: 1 S/N: 1

# # # # # # # # 1 # 1 # 1 #

# 1 # # 1 # 1 # # # #

# 1 # # 1 # 1 # # # #

# 1 # # 1 # 1 #

The following steps require flow in the pipe. Flow signal readings should be taken while holding the flow rate constant if possible, otherwise, take the various output readings as quickly as possible.

9.

Frequency output(s):
Avg = green, Top = white Bottom = orange

Avg Freq. (HZ): Avg Freq. (VDC): Top Turbine (HZ): Top Turbine (VDC): Bottom Turbine (HZ): Bottom Turbine (VDC): Calculated Flow Rate:

Hz VDC

Hz VDC

Hz VDC

Hz VDC

Hz VDC

Hz VDC

Hz VDC

Hz VDC

Hz VDC

Hz VDC

Hz VDC

Hz VDC

GPM

GPM

GPM

GPM

Analog or binary outputs


4-20 mA signal: 0-10 V signal: Scaled output interval or divided output frequency Calculated Flow Rate:
MA VDC MA VDC MA VDC MA VDC

10.

GPM

GPM

GPM

GPM

11.

Flow rate displayed by control system

GPM

GPM

GPM

GPM

Owners Manual for ONICON Insertion Turbine Flow Meters September 27, 2001

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4.4

TROUBLESHOOTING GUIDE

NOTE: Also refer to the START-UP and COMMISSIONING GUIDE located on the preceding pages. REPORTED PROBLEM

POSSIBLE SOLUTIONS
Verify that meter is inserted correctly into the pipe. Verify that the electronics enclosure is parallel with the pipe. Verify 24 V supply voltage. Verify correct wiring to control system (see wiring diagram). Check turbine(s) for debris. Verify pipe size. Contact factory if pipe size is different from calibration tag. Verify that meter is inserted correctly into the pipe. Verify that the electronics enclosure is parallel with the pipe. Verify correct wiring to control system (see wiring diagram). Confirm that output signals are consistent (frequency vs. analog, etc.)

No Signal

Reading is too high or too low

Confirm that control system is programmed for correct flow range or scale factor.
Check turbine(s) for debris.

Check for ground loop or offset voltage:

Analog signal seems high or low and does not correspond to frequency output Control system displays flow rate, but no flow rate indication on local display module or BTU Meter

Disconnect analog signal input to control system and measure analog outputs directly from the flow meter.
Re-connect signal input to control system and measure the analog signals again. Any difference between these readings indicates a potential ground loop or offset voltage. Please contact ONICON for further assistance.

Verify that all wires from flow meter were connected to the display module or BTU Meter.
The frequency output wire (green) must be connected for any ONICON Display or BTU Meter.

For technical assistance, contact ONICON Incorporated at (727) 447-6140.

Owners Manual for ONICON Insertion Turbine Flow Meters September 27, 2001

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SECTION 5.0: ANALOG ADJUSTMENT PROCEDURE


ONICON electronic circuits are designed and tested to ensure long life with minimal drift; therefore, you should not expect to make regular field adjustments or calibrations. However, it will be necessary for you to rescale the analog output under the following conditions:

The turbine was replaced with a new one having a significantly different meter factor. You wish to change the flow rate represented by the analog output. An analog output meter is being moved to a different size pipe.

ONICON will do all of these recalibrations at low cost, with a one or two day turnaround. However, we have included this section for those instances where you cannot return the meter or simply want to do the work yourself. We will be happy to work through the procedure with you on the phone, if you desire.

While these adjustments are not complicated, they are crucial to the accuracy of the flow meter. Therefore, any adjustments should be made only by qualified personnel having an understanding of flow equations and experience with control systems. 5.1 GENERAL DISCUSSION

ONICON Insertion Flow Meters contain circuitry which measures the velocity of a flowing stream of water, or water based liquid, by sensing the rotational rate of a freely rotating axial turbine, which is immersed in the flow stream. As each turbine blade passes a fixed electrode, an electronic pulse is produced by the circuitry. In the case of single turbine meters, the pulse rate is then calibrated in terms of the number of pulses per gallon in whatever size pipe the user has selected. This number is called the METER FACTOR. For example an Insertion Flow Meter might have a meter factor of 31.3 PPG (Pulses Per Gallon) in 3 pipe. This is the calibrated frequency output signal.

Dual turbine meters are basically the same except that the pulse rates from the upper and lower turbines are electronically averaged and the calibration is done using this average output signal.

This frequency output signal can be used directly by some data acquisition systems. Other systems require an analog representation of flow rate. For these systems the frequency output signal is processed by the optional analog output card and another calibration is then done on the 4-20 mA and 0-10 V analog output signal.

Owners Manual for ONICON Insertion Turbine Flow Meters September 27, 2001

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5.2

ANALOG ADJUSTMENT PROCEDURE

This procedure adjusts both 4-20 mA & 0-10 V output signals. It is limited to meters with serial numbers 115692 and higher. Contact the factory for assistance if your meters serial number is below 115692. 5.21 Equipment Required 5.22 Voltmeter Pulse Generator 24 V Power Supply

Procedure 1. Determine the input frequency required to simulate the desired maximum flow rate using the equation below:

Where: F = Input Frequency (Hz) R = Maximum Flow Rate (GPM) MF = Meter Factor* (Pulses Per Gallon) F = R x MF 60 *The meter factor is written on a calibration tag attached to each meter and is also recorded on the calibration data sheet. Please contact the factory if you cannot located the meter factor, or if you wish to use the meter in a different pipe size. 2. Remove the flow meter from the pipe and make sure the electrode and the surrounding area are dry. 3. Choose the input frequency range (Hz) from the table on the next page and set the appropriate range selection jumper. Refer to Appendix A for the internal wiring diagram of your model. 4. Connect the pulse generator output lead to the test signal input lead on the analog card, and connect the pulse generator ground lead to the black ground wire in the flow meter cable. Set the output to a 15 V P-P square wave at the frequency determined in step #1. 5. Set the DC voltmeter to the 0-10 V scale and connect the (+) lead to the brown wire in the flow meter cable. Connect the (-) lead from the voltmeter to the black ground wire in the flow meter cable. 6. Connect the red and black wires in the flow meter cable to the (+) and (-) terminals of the 24 V power supply respectively. Apply power.

Owners Manual for ONICON Insertion Turbine Flow Meters September 27, 2001

20

7. Adjust the span potentiometer on the analog card to produce a 10 V reading on the voltmeter. NOTE: The frequency ranges in the table are a starting point, and since they vary with electronic component tolerance, it may be necessary to change the jumper position once rescaling is started. If the range of adjustment of the span potentiometer is not sufficient to produce the desired 10 VDC, change the jumper position as follows: VOLTAGE READING TOO HIGH: Choose the next lower jumper position. VOLTAGE READING TOO LOW: Choose the next higher jumper position. 8. The flow meter is now rescaled. Disconnect all equipment, replace the cover and reinstall the flow meter.

Analog Range Switch Settings INPUT FREQUENCY (Hz) AT MAXIMUM FLOW RATE SWITCH POSITION SINGLE/DUAL TURBINE

Over 248 124 248 62 123 31 61 15 30 Under 15

Hz Hz Hz Hz Hz Hz

1 2 3 4 5 6

Owners Manual for ONICON Insertion Turbine Flow Meters September 27, 2001

21

APPENDIX A

User Connections and Internal Wiring Diagrams

Owners Manual for ONICON Insertion Turbine Flow Meters September 27, 2001

22

FLOW METER WIRING INFORMATION


User Connections for Models with Frequency Output Models: F-1100, F-1200, FB-1200 & F-1300
Sin -11 gle 00 Tur bin e F Du -120 al T 0 urb ine Bi- B-12 Dir ect 00 ion al

Inli 00 ne

-13

Wiring Information
WIRE COLOR CODE
(+) 24 4 V AC/DC supply voltage () Common ground (Common with pipe ground) (+) Frequency output signal: 0-15 V peak pulse Dry contact directional output - indicates flow direction

NOTES
Connect to power supply positive Connect to power supply negative Output frequency is typically below 200 Hz, but can be up to 300 Hz Contact closed when flow is in direction of arrow on meter

RED* BLACK

GREEN

GRAY VIOLET

DIAGNOSTIC SIGNALS

ORANGE Bottom turbine frequency WHITE Top turbine frequency

These signals are for diagnostic purposes connect to local display or BTU meter

F-1100 / F-1200 / F-1300 Wiring Diagram


Flow Meter Connections to ONICON Display or BTU Meter

FB-1200 Wiring Diagram


Connections to ONICON Display or BTU Meter
ONICON Display or BTU Meter + 24 V FREQUENCY INPUT GROUND TOP TURBINE BOTTOM TURBINE DIRECTIONAL CONTACTS RED GREEN

FLOW METER

ONICON Display or BTU Meter RED GREEN BLACK WHITE ORANGE + 24 V FREQUENCY INPUT GROUND TOP TURBINE BOTTOM TURBINE

FLOW METER

BLACK WHITE ORANGE GRAY VIOLET

F-1200 only

NOTES:

* 1.

Serial Numbers 115691 and earlier require 24 VDC. Serial Numbers 115692 and higher can accept 24 V AC/DC. 2. Black wire is common with the pipe (typically earth ground). 3. For ONICON display module or BTU meter, connect all wires provided. Refer to wiring diagram provided with display or BTU meter.

0271

1500 North Belcher Road, Clearwater, Florida 33765 Tel (727) 447-6140 Fax (727) 442-5699 www.onicon.com E-mail: sales@onicon.com

8-20-01

WIRING DIAGRAM INTERNAL CONNECTIONS FOR FREQUENCY OUTPUT FLOW METERS MODELS F-1100 / F-1200 / F-1300
For use with serial numbers 115692 and later

FREQUENCY BOARD

SENSING BOARD
TOP TURBINE: F-1200 ONLY (WHITE WIRE)

TEST SIGNAL INPUT

BOTTOM TURBINE: F-1200 ONLY (ORANGE WIRE)

BLACK WIRE (BOARD TO BOARD) GREEN WIRE (BOARD TO BOARD) RED WIRE (BOARD TO BOARD) FREQUENCY OUTPUT (GREEN WIRE) COMMON GROUND (BLACK WIRE) +24V AC/DC SUPPLY (RED WIRE)

EXTERNAL CABLE NOTE: INTERNAL CONNECTIONS OMITTED FOR CLARITY

NOTES:

0066-1

1500 North Belcher Road, Clearwater, Florida 33765 Tel (727) 447-6140 Fax (727) 442-5699 www.onicon.com E-mail: sales@onicon.com

EXTERNAL CABLE CONNECTIONS


8-22-00

FLOW METER WIRING INFORMATION


User Connections for Models with Non-Isolated Analog Outputs Models: F-1110, F-1210, FB-1210 & F-1310
Sin -11 gle 10 Tur bin e F Du -121 al T 0 urb ine Bi- B-12 Dir ect 10 ion al

Inli 10 ne

-13

Wiring Information
WIRE COLOR CODE
(+) 24 4 V AC/DC supply voltage () Common ground (Common with pipe ground) (+) Frequency output signal: 0-15 V peak pulse (+) Analog signal: 4-20 mA (non-isolated) (+) Analog signal: 0-10 V (non-isolated) (Can also be ordered as 0-5 V) Dry contact directional output - indicates flow direction

NOTES
Connect to power supply positive Connect to power supply negative & analog input ground Required when meter is connected to local display or BTU meter

RED* BLACK

GREEN

BLUE

BROWN

Both signals may be used independently (unless 0-5 V output is ordered)

GRAY VIOLET

Contact closed when flow is in direction of arrow on meter

DIAGNOSTIC SIGNALS

ORANGE Bottom turbine frequency WHITE Top turbine frequency

These signals are for diagnostic purposes connect to local display or BTU meter

F-1110 / F-1210 / F-1310 Wiring Diagram


Connections to a Control System (No Display or BTU Meter)
Power Source

FB-1210 Wiring Diagram


Connections to a Control System (No Display or BTU Meter)
Power Source RED + 24 V COM Control System BLUE BROWN GRAY VIOLET BINARY (DIGITAL) INPUT (Direction) OR SIGNAL GROUND ANALOG INPUT BLACK

FLOW METER

BLACK

COM Control System

BLUE BROWN OR

SIGNAL GROUND ANALOG SIGNAL INPUT

NOTES:

* 1.

Serial Numbers 115691 and earlier require 24 VDC. Serial Numbers 115692 and higher can accept 24 V AC/DC. 2. Black wire is common with the pipe (typically earth ground). 3. For ONICON display module or BTU meter, connect all wires provided. Refer to wiring diagram provided with display or BTU meter. 4. This is NOT a "loop-powered" instrument. DO NOT connect power to any of the signal output wires (blue, brown, green, orange or white)

0272

1500 North Belcher Road, Clearwater, Florida 33765 Tel (727) 447-6140 Fax (727) 442-5699 www.onicon.com E-mail: sales@onicon.com

FLOW METER

RED

+ 24 V

8-20-01

WIRING DIAGRAM INTERNAL CONNECTIONS FOR NON-ISOLATED ANALOG OUTPUT FLOW METERS MODELS F-1110 / F-1210 / F-1310
For use with serial numbers 115692 and later

ANALOG BOARD

SENSING BOARD
TOP TURBINE: F-1210 ONLY (WHITE WIRE) BOTTOM TURBINE: F-1210 ONLY (ORANGE WIRE) 4-20 mA OUTPUT (BLUE WIRE) 0-10 V OUTPUT (BROWN WIRE) FREQUENCY OUTPUT (GREEN WIRE) COMMON GROUND (BLACK WIRE)

RANGE JUMPER (FACTORY SELECTED) 4 mA ZERO ADJUST BLACK WIRE (BOARD TO BOARD) GREEN WIRE (BOARD TO BOARD) RED WIRE (BOARD TO BOARD)

10 V & 20 mA SPAN ADJUST

24V AC/DC SUPPLY (RED WIRE) EXTERNAL CABLE NOTE: CONNECTIONS OMITTED FOR CLARITY

NOTES:

0016-2

1500 North Belcher Road, Clearwater, Florida 33765 Tel (727) 447-6140 Fax (727) 442-5699 www.onicon.com E-mail: sales@onicon.com

10-15-01

EXTERNAL CABLE CONNECTIONS

TEST SIGNAL INPUT

FLOW METER WIRING INFORMATION


User Connections for Models with Isolated Analog Outputs Models: F-1111, F-1211, FB-1211 & F-1311
Sin -11 gle 11 Tur bin e F Du -121 al T 1 urb ine Bi- B-12 Dir ect 11 ion al Inli 11 ne

-13

Wiring Information
WIRE COLOR CODE
(+) 24 4 V AC/DC supply voltage () Common ground (Common with pipe ground) (+) Frequency output signal: 0-15 V peak pulse (+) Analog signal: 4-20 mA (isolated) (+) Analog signal: 0-10 V (isolated) (Can also be ordered as 0-5 V)

NOTES
Connect to power supply positive Connect to power supply negative Required when meter is connected to local display or BTU meter

RED* BLACK

GREEN

BLUE

BROWN

Both signals may be used independently (unless 0-5 V output is ordered)

YELLOW () Isolated ground


GRAY VIOLET Dry contact directional output - indicates flow direction

Use for analog signals only Contact closed when flow is in direction of arrow on meter

DIAGNOSTIC SIGNALS

ORANGE Bottom turbine frequency


WHITE Top turbine frequency

These signals are for diagnostic purposes connect to local display or BTU meter

F-1111 / F-1211 / F-1311 Wiring Diagram


Connections to a Control System (No Display or BTU Meter)
Power Source

FB-1211 Wiring Diagram


Connections to a Control System (No Display or BTU Meter)
Power Source RED BLACK + 24 V COM Control System OR ANALOG INPUT SIGNAL GROUND

FLOW METER

RED BLACK BLUE BROWN YELLOW OR

FLOW METER

+ 24 V COM Control System ANALOG SIGNAL INPUT SIGNAL GROUND

BLUE BROWN YELLOW

GRAY VIOLET BINARY (DIGITAL) INPUT (Direction)

NOTES:

* 1.

Serial Numbers 115691 and earlier require 24 VDC. Serial Numbers 115692 and higher can accept 24 V AC/DC. 2. Black wire is common with the pipe (typically earth ground). 3. For ONICON display module or BTU meter, connect all wires provided. Refer to wiring diagram provided with display or BTU meter. 4. This is NOT a "loop-powered" instrument. DO NOT connect power to any of the signal output wires (blue, brown, green, orange or white)

0273

1500 North Belcher Road, Clearwater, Florida 33765 Tel (727) 447-6140 Fax (727) 442-5699 www.onicon.com E-mail: sales@onicon.com

8-20-01

WIRING DIAGRAM INTERNAL CONNECTIONS FOR ISOLATED ANALOG OUTPUT FLOW METERS MODELS F-1111 / F-1211 / F-1311
For use with serial numbers 115692 and later

ISOLATED ANALOG BOARD

SENSING BOARD
TOP TURBINE: F-1211 ONLY (WHITE WIRE)

TEST SIGNAL INPUT RANGE JUMPER (FACTORY SELECTED) 4 mA ZERO ADJUST BLACK WIRE (BOARD TO BOARD) GREEN WIRE (BOARD TO BOARD) RED WIRE (BOARD TO BOARD)

BOTTOM TURBINE: F-1211 ONLY (ORANGE WIRE) ISOLATED GROUND (YELLOW WIRE) 4-20 mA OUTPUT (BLUE WIRE) 0-10 V OUTPUT (BROWN WIRE) FREQUENCY OUTPUT (GREEN WIRE) COMMON GROUND (BLACK WIRE) +24V AC/DC SUPPLY (RED WIRE)

10 V & 20 mA SPAN ADJUST

EXTERNAL CABLE NOTE: INTERNAL CONNECTIONS OMITTED FOR CLARITY

NOTES:

0068-2

1500 North Belcher Road, Clearwater, Florida 33765 Tel (727) 447-6140 Fax (727) 442-5699 www.onicon.com E-mail: sales@onicon.com

EXTERNAL CABLE CONNECTIONS


8-22-00

FLOW METER WIRING INFORMATION


User Connections for Models with Divided Output Models: F-1120, F-1220, FB-1220 & F-1320
Sin -11 gle 20 Tur bin e F Du -122 al T 0 urb ine Bi- B-12 Dir ect 20 ion al

Inli 20 ne

-13

Wiring Information
WIRE COLOR CODE
(+) 24 4 V AC/DC supply voltage () Common ground (Common with pipe ground) (+) Frequency output signal: 0-15 V peak pulse

NOTES
Connect to power supply positive Connect to power supply negative Required when meter is connected to local display or BTU meter Output can be divided by any binary number up to 4096 to meet frequency limitations of control system

RED* BLACK

GREEN

BLUE Dry contact divided output - indicates flow rate

BROWN

GRAY VIOLET

Dry contact directional output - indicates flow direction

Contact closed when flow is in direction of arrow on meter

DIAGNOSTIC SIGNALS

ORANGE Bottom turbine frequency WHITE Top turbine frequency

These signals are for diagnostic purposes connect to local display or BTU meter

F-1120 / F-1220 / F-1320 Wiring Diagram


Connections to a Control System (No Display or BTU Meter)
Power Source

FB-1220 Wiring Diagram


Connections to a Control System (No Display or BTU Meter)
Power Source RED

24 V COM
Control System

FLOW METER

BLACK

COM Control System

FLOW METER

RED

+ 24 V

BLACK

BLUE BROWN GRAY VIOLET BINARY (DIGITAL) INPUT (Direction) BINARY (DIGITAL) INPUT (Rate)

BLUE BROWN BINARY (DIGITAL) INPUT

NOTES:

* 1.

Serial Numbers 115691 and earlier require 24 VDC. Serial Numbers 115692 and higher can accept 24 V AC/DC. 2. Black wire is common with the pipe (typically earth ground). 3. For ONICON display module or BTU meter, connect all wires provided. Refer to wiring diagram provided with display or BTU meter.

0274

1500 North Belcher Road, Clearwater, Florida 33765 Tel (727) 447-6140 Fax (727) 442-5699 www.onicon.com E-mail: sales@onicon.com

8-20-01

WIRING DIAGRAM INTERNAL CONNECTIONS FOR DIVIDED OUTPUT FLOW METERS MODELS F-1120 / F-1220 / F-1320
For use with serial numbers 115692 and later

DIVIDER BOARD
1:1 JUMPER AT THIS END

SENSING BOARD

TEST SIGNAL INPUT 1:1 JUMPER AT THIS END DIVIDER JUMPER BLOCK BLACK WIRE (BOARD TO BOARD) GREEN WIRE (BOARD TO BOARD) RED WIRE (BOARD TO BOARD)

BOTTOM TURBINE: F-1220 ONLY (ORANGE WIRE) (BROWN WIRE) DIVIDED OUTPUT SWITCH (BLUE WIRE) FREQUENCY OUTPUT (GREEN WIRE) COMMON GROUND (BLACK WIRE)

AVAILABLE BINARY DIVIDER SELECTIONS SELECT ONLY ONE VALUE OR THE DIVISION WILL NOT BE CORRECT

24V AC/DC SUPPLY (RED WIRE)

1:1 1:2 1:4 1:8 1:16 1:32 1:64 1:128 1:256 1:512 1:1024 1:2048 1:4096 NOTES:

EXTERNAL CABLE NOTE: INTERNAL CONNECTIONS OMITTED FOR CLARITY

0069-1

1500 North Belcher Road, Clearwater, Florida 33765 Tel (727) 447-6140 Fax (727) 442-5699 www.onicon.com E-mail: sales@onicon.com

8-22-00

EXTERNAL CABLE CONNECTIONS

TOP TURBINE: F-1220 ONLY (WHITE WIRE)

FLOW METER WIRING INFORMATION


User Connections for Models with Scaled Output Models: F-1130, F-1230, FB-1230 & F-1330
Sin -11 gle 30 Tur bin e F Du -123 al T 0 urb ine Bi- B-12 Dir ect 30 ion al

Inli 30 ne

-13

Wiring Information
WIRE COLOR CODE
(+) 24 4 V AC/DC supply voltage () Common ground (Common with pipe ground) (+) Frequency output signal: 0-15 V peak pulse

NOTES
Connect to power supply positive Connect to power supply negative Required when meter is connected to local display or BTU meter Scaled to provide one pulse per volumetric unit
Examples: 1 pulse per 10 gal. 1 pulse per 100 gal.

RED* BLACK

GREEN

BLUE Dry contact scaled output BROWN

GRAY VIOLET

Dry contact directional output - indicates flow direction

Contact closed when flow is in direction of arrow on meter

DIAGNOSTIC SIGNALS

ORANGE Bottom turbine frequency WHITE Top turbine frequency

These signals are for diagnostic purposes connect to local display or BTU meter

F-1130 / F-1230 / F-1330 Wiring Diagram


Connections to a Control System (No Display or BTU Meter)
Power Source

FB-1230 Wiring Diagram


Connections to a Control System (No Display or BTU Meter)
Power Source RED + 24 V COM Control System BLUE BROWN GRAY VIOLET BINARY (DIGITAL) INPUT (Direction) BINARY (DIGITAL) INPUT (Rate) BLACK

FLOW METER

BLACK

COM Control System

BLUE BROWN BINARY (DIGITAL) INPUT

NOTES:

* 1.

Serial Numbers 115691 and earlier require 24 VDC. Serial Numbers 115692 and higher can accept 24 V AC/DC. 2. Black wire is common with the pipe (typically earth ground). 3. For ONICON display module or BTU meter, connect all wires provided. Refer to wiring diagram provided with display or BTU meter. 4. This is NOT a "loop-powered" instrument. DO NOT connect power to any of the signal output wires (blue, brown, green, orange or white)

0275

1500 North Belcher Road, Clearwater, Florida 33765 Tel (727) 447-6140 Fax (727) 442-5699 www.onicon.com E-mail: sales@onicon.com

FLOW METER

RED

+ 24 V

8-20-01

WIRING DIAGRAM INTERNAL CONNECTIONS FOR SCALED OUTPUT FLOW METERS MODELS F-1130 / F-1230 / F-1330
For use with serial numbers 115692 and later

SCALER BOARD

SENSING BOARD
TOP TURBINE: F-1230 ONLY (WHITE WIRE) BOTTOM TURBINE: F-1230 ONLY (ORANGE WIRE) (BROWN WIRE) SCALED OUTPUT SWITCH (BLUE WIRE) FREQUENCY OUTPUT (GREEN WIRE)

TEST SIGNAL INPUT


1 2 3 4 5 6 7 8 9 10 11 12

1:1 SWITCH AT THIS END SCALER SWITCH BLOCK BLACK WIRE (BOARD TO BOARD) GREEN WIRE (BOARD TO BOARD) RED WIRE (BOARD TO BOARD)

50 ms 300 ms CONTACT CLOSURE DURATION JUMPER

COMMON GROUND (BLACK WIRE) +24V AC/DC SUPPLY (RED WIRE)

SETTING DIVISION RATIO Available binary scaler selections 1:1 1:2 1:4 1:8 1:16 1:32 1:64 1:128 1:256 1:512 1:1024 1:2048
0070-1

EXTERNAL CABLE NOTE: INTERNAL CONNECTIONS OMITTED FOR CLARITY

To set division ratio, turn ON each switch that is required to produce an arithmetic sum equal to the desired ratio. For example:
SW VAL

NOTES:

1 2 3 4 5 6 7 8 9 10 11 12

1 2 4 8 16 32 64 128 256 512+64+32+16+4+1=629 512 1024 SET SWITCHS 2048 10, 7, 6, 5, 3, & 1 TO "ON"
8-22-00

DESIRED RATIO = 629 Subtract the largest possible switch value. 629 - 512=117 117 - 64=53 53 - 32=21 21 - 16=5 5 - 4=1 1 - 1=0

1500 North Belcher Road, Clearwater, Florida 33765 Tel (727) 447-6140 Fax (727) 442-5699 www.onicon.com E-mail: sales@onicon.com

EXTERNAL CABLE CONNECTIONS

APPENDIX B

Turbine Assembly Detail Drawings

Owners Manual for ONICON Insertion Turbine Flow Meters September 27, 2001

23

TURBINE ASSEMBLY DETAILS for ALL MODELS IN F-1100 SERIES

2-56 Stainless, Phillips Head Screws. Clean phillips head grooves with a sharp instrument before trying to loosen screws in a meter which has been in service. Turbine must be free to slide back and forth on the shaft with at least .015" of movement.

UPPER SUPPORT

TUNGSTEN CARBIDE TURBINE SHAFT

SUPPORT POST

SAPPHIRE JEWEL THRUST BEARINGS

Replace turbines in the same end-for-end relationship to the direction of flow. (Mark one end of the turbine and the same end of the upper support with a permanent felt tip marker) After re-assembly, test the turbine for free rotation by gently blowing on the turbine PARA LLEL TO ITS SHAFT. The turbine must spin freely and must have a minimum of .015" of free end play.

TURBINE ROTOR

LOWER SUPPORT

SAPPHIRE JEWEL RADIAL BEARINGS If these bearings are removed from the turbine or loosened at all, the flow meter must be returned to the factory for recalibration or the turbine must be replaced.

0098

1500 North Belcher Road, Clearwater, Florida 33765 Tel (727) 447-6140 Fax (727) 442-5699 www.onicon.com E-mail: sales@onicon.com

7-18-97

TURBINE ASSEMBLY DETAILS for ALL MODELS IN F-1200 SERIES

2-56 STAINLE SS, PHILLIPS HEAD SCREWS. Clean phillips head grooves with a sharp instrument before trying to loosen screws in a meter which has been in service. Turbines must be free to slide back and forth on the shaft with at least .015" of movement.

UPPER SUPPORT

SAPPHIRE JEWEL THRUST BEARINGS

REMOVABLE SUPPORT POST

Replace turbines in the same upper or lower location and in the same end-forend relationship to the direction of flow. (Mark one end of each turbine and the same end of the upper support with a permanent felt tip marker) After re-assembly, test the turbines for free rotation by gently blowing on the turbines PARALLEL TO THEIR SHAFTS. The turbines must spin freely and must have a minimum of .015" of free end play.

TURBINE ROTORS NON-REMOVABLE SUPPORT POST

LOWER SUPPORT

SAPPHIRE JEWEL RADIAL BEARINGS If these bearings are removed from the turbines or loosened at all, the flow meter must be returned to the factory for recalibration or the turbines must be

TUNGSTEN CARBIDE TURBINE SHAFT

0099-1

1500 North Belcher Road, Clearwater, Florida 33765 Tel (727) 447-6140 Fax (727) 442-5699 www.onicon.com E-mail: sales@onicon.com

8-16-00

APPENDIX C

Conditions of Sale

Owners Manual for ONICON Insertion Turbine Flow Meters September 27, 2001

24

CONDITIONS OF SALE
1. ACCEPTANCE: The following Conditions of Sale apply to all sales of ONICONs products. These provisions shall apply even if ONICON fails to object to provisions appearing on, incorporated by, referenced in, or attached to Buyers purchase order form. Buyers acceptance of delivery of ONICONs products constitutes its acceptance of these Conditions of Sale. 2. DELIVERY AND TITLE: All product shipments are F.O.B. shipping point and title passes to the Buyer at the time ONICON delivers the merchandise to the carrier. Risk of loss or damage to the product passes to the Buyer at the time ONICON delivers the product to the carrier. The Buyer immediately upon receipt should inspect all shipments, and should there be any evidence of damage or loss in transit, Buyer must file claims or tracers upon carrier. ONICON will assist in tracing shipments upon request. 3. LIMITED WARRANTY: ONICON warrants that for a period of two (2) years following the date of original shipment of an ONICON product: (i) the product will conform to ONICONs standard written specifications applicable to such product in effect on the date of Buyers order, or as modified by ONICONs quotation or Buyers purchase order accepted by ONICON, (ii) the product will be free from defects in workmanship, and (iii) that ONICON has title to the product prior to shipment to the Buyer; provided, however, that the warranties provided herein shall be void and may not apply in the event Buyer misuses or damages a product, including, but not limited to, any use by the Buyer of a product for an application other than one of a type approved by ONICON. ONICONs sole liability and Buyers sole remedy for any breach of the foregoing warranty is for ONICON to repair or replace, at ONICONs option, any defective product that is returned to ONICON during the warranty period. EXCEPT AS MAY BE SPECIFICALLY AGREED BY ONICON IN WRITING IN RELATION TO EACH SALE, NO OTHER WARRANTIES SHALL APPLY, WHETHER EXPRESSED, IMPLIED OR STATUTORY, AND THERE SHALL BE NO IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE. 4. REMEDIES: ONICONs OBLIGATION UNDER THE FOREGOING WARRANTIES IS LIMITED SOLELY TO REPAIR OR REPLACEMENT, AT ONICONs OPTION, OF DEFECTIVE OR NONCONFORMING PRODUCTS. ONICON SHALL NOT BE LIABLE FOR CONSEQUENTIAL, INDIRECT, PUNITIVE, INCIDENTAL, OR SPECIAL DAMAGES WHETHER FOUND ON CONTRACT, TORT OR ANY OTHER THEORY OF LAW. No products shall be returned to ONICON without its prior consent and transportation and insurance costs shall be prepaid. Any repair or replacement of ONICONs products under the foregoing warranty will be at no charge to the Buyer provided such repair is done at the ONICON factory or authorized service center. ONICON products that are repaired or replaced under this warranty will be returned to Buyer via the same method of shipment use to return the product to ONICON. Repair or replacement of ONICON products is conditioned upon ONICONs acknowledgement of any alleged defect or nonconformance during the warranty period and issuance of a Return Authorization number. All product returns must reference the Return Authorization number on the outside of the shipping carton and on any paperwork referencing the return. 5. PRICES AND PAYMENT TERMS: The prices set forth in the most recent quote or acknowledgement as applicable, supersede all previous prices or quotations. All quotations are subject to change or withdrawal without notice except as may be specifically noted on the face of the quotation. The prices shown do not include sales, excise or government charges payable by ONICON to Federal, State, or local authority. Any such tax or charge now or hereafter imposed upon the sale or shipment of the products under this contract will be added to the purchase price. Buyer agrees to reimburse ONICON for such tax or charge or provide ONICON with an acceptable exemption certificate. Payment of invoices will be due 30 days from the date of shipment of the products contained therein. In the event that payment of an invoice is not received by the invoice due date, ONICON will assess a late fee not to exceed 1.5% per month or 18% per year, or the maximum allowable by law whichever is lower. 6. CANCELLATION: Buyer may cancel its order, or any part of it, by sending written notice of cancellation to ONICON and paying a reasonable cancellation fee as determined by ONICON. The reasonable cancellation fee will reflect, among other factors, the expenses already incurred and commitments made by ONICON, sales and administrative costs and profit as determined by ONICON. If Buyer received a reduced price based on the quantity of products ordered, but has not purchased the applicable quantity at the time of cancellation, Buyer will pay the price it would have paid had ONICONs sale price been based on the quantity actually purchased. 7. CHANGES: If Buyer makes any changes in its drawings, designs, or specifications applicable in any contract with ONICON that cause an increase or decrease in the cost of performance of the contract, or if such changes result in rework or obsolescence, an equitable adjustment shall be made to the contract. Such changes are subject to ONICONs prior written consent. 8. EXCUSABLE DELAY: ONICON shall under no circumstance be responsible for failure to fill any order or orders when due to: fires, floods, riots, strikes, freight embargoes or transportation delays, shortage of labor, inability to secure fuel, material supplies, or power at current price or on account of shortages thereof, acts of God or of the public enemy, any existing or future laws or acts of the Federal or State Government (including specifically, but not exclusively, and orders, rules or regulations issued by any official or agency of any such government) affecting the conduct of ONICONs business with which ONICON in its judgment and discretion deems it advisable to comply as a legal or patriotic duty, or due to any cause beyond ONICONs reasonable control. 9. PATENTS: ONICON shall defend all suits or proceedings brought against Buyer or its customers arising from claimed infringements of any patent, trademark, service mark or copyright for any product furnished by ONICON and shall indemnify it against all costs, fees, and damages on the condition Buyer promptly notifies ONICON in writing and provides information and assistance to enable ONICON to conduct the defense, provided that ONICON shall have no such obligation in case of infringement resulting from ONICONs conformance to special requirements of Buyer. If ONICON is not able to settle any such suit or proceeding on acceptable terms, ONICON may, at its option, require return of the infringing product and refund the purchase price to Buyer less a reasonable allowance for depreciation or use. 10. FAIR LABOR STANDARDS ACT: ONICON represents that all products delivered under this contract are furnished in accordance with the applicable provisions of the Fair Labor Standards Act as amended. 11. APPLICABLE LAW: This document and any resulting contract shall be governed by and construed in accordance with the laws of the State of Florida. The courts of the State of Florida and the federal courts located in Florida shall have jurisdiction and venue with respect to litigation to this contract. In the event of litigation, the prevailing party shall be entitled to recover attorneys fees and costs from the non-prevailing party, including appellate attorneys fees. 12. MODIFICATIONS: These Conditions of Sale along with the prices, quantities delivery schedules and other provisions and instructions in applicable quotations by shall constitute the entire agreement between ONICON and Buyer pertaining to any resulting contract. They can be modified only in writing.

Owners Manual for ONICON Insertion Turbine Flow Meters September 27, 2001

25